Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual — part 12
2B-14
Chapter 2 Part B V6 engine
STRETCHED
BOLT
UNSTRETCHED BOLT
12.18 Place a precision straightedge along the cylinder head bolt
thread profile as shown, if any part of the bolt threads are not on
the straightedge, the bolt is stretched and must be replaced
12.19a Checking the cylinder head-to-engine block gasket
surface for warpage
12.19b Checking the engine block head gasket surface
for warpage
12.22 When installing the head gasket onto the block, make sure
all passages in the block align with the holes in the gasket
ing and tapping the wood with a hammer or
by prying the head with a prybar placed care-
fully on a casting protrusion. Note: If further
disassembly of the cylinder head is required,
refer to Part C of this Chapter.
17
Remove all traces of old gasket material
from the block and head. Special gasket
removal solvents that soften gaskets and
make removal much easier are available at
auto parts stores. Caution: The cylinder head
is aluminum, be very
careful not to gouge the
sealing surfaces. When working on the block,
place clean shop rags into the cylinders to
help keep out debris. Use a vacuum to
remove any contamination from the engine.
Use a tap of the correct size to chase the
threads in the engine block. Clean and
inspect all threaded fasteners for damage.
18 Inspect the cylinder head bolt threads
for "necking," where the diameter of threads
narrow due to bolt stretching (see illustra-
tion). If any cylinder head bolt exhibits dam-
age or necking, it must be replaced.
19
Using a precision straightedge and
feeler gauge, check all gasket surfaces for
warpage (see illustrations). If the warpage
on any surface exceeds the limits listed in
this Chapter's Specifications, the discrepant
component must be replaced or resurfaced
by an automotive machine shop.
20
Refer to Part C of this Chapter for clean-
ing and inspection of the cylinder head.
12.23 Install the head bolt washers
as shown
Installation
Refer to illustrations 12.22, 12.23 and 12.24
21
Install the camshaft(s) if removed (see
Section 10).
22
Place a new gasket on the engine block
(see illustration). Use no sealer unless indi-
cated by the gasket manufacturer. Note any
directions printed on the gasket such as
"Front" or "This side up." Place the cylinder
head(s) in position on the engine block.
23 Install the washers onto the cylinder
head bolts as shown (see illustration). Apply
clean engine oil to the cylinder head bolt
threads and install them into the cylinder
head.
24
Tighten the cylinder head bolts in the
sequence shown (see illustration) progress-
12.24 Cylinder head bolt
TIGHTENING sequence
ing in three stages to the torque listed in this
Chapter's Specifications.
25
The remaining installation steps are the
reverse of removal.
26
Refill the cooling system and check all
fluid levels (see Chapter 1 if necessary).
27
Start the engine and let it run until nor-
mal operating temperature is reached. Check
for leaks and proper operation.
Chapter 2 Part B V6 engine
2B-15
13.5 Engine oil dipstick tube mounting
bolt (arrow) - exhaust manifold heat shield
removed for clarity
13.10 If the pan is stuck, tap it with a soft-
face hammer or place a wood block
against the pan and tap the wood block
with a hammer to jar it loose
13.11a Lower the front of the oil pan to
access the oil pump pick-up tube and
remove the mounting bolts .. .
2B
13.11 b . . . then remove the oil pump pick up tube from
the pump body
13.12 With the oil pump pick up tube removed, the oil pan can
then be withdrawn over the engine support module (arrow)
13 Oil pan - removal and installation
Removal
Refer to illustrations 13.5, 13.10, 13.11a,
13.11b, 13.12, 13.13a and 13.13b
1
Disconnect the negative battery cable
from the ground stud on the left shock tower
(see Chapter 5, Section 1).
2
Raise the vehicle and support it securely
on jackstands.
3
Remove the accessory drivebelt splash
shield (see Chapter 1).
4
Drain the engine oil (see Chapter 1).
5
Remove the dipstick tube (see illustra-
tion).
6
Remove the starter motor (see Chap-
ter 5).
7
Remove the engine-to-transmission
support brackets.
8
Remove the exhaust manifold cross-
over pipe (see Section 5).
9
Remove the transaxle inspection cover.
10
Remove the mounting bolts and sepa-
rate the oil pan from the engine block enough
to facilitate oil pump pickup tube removal. If
the pan is stuck, tap it with a soft-face ham-
mer (see illustration) or place a wood block
13.13a Thoroughly clean the oil pan and
engine block gasket surfaces with a
scraper to remove all traces of old
gasket material
against the pan and tap the wood block with
a hammer. Caution: If you're wedging some-
thing between the oil pan and the engine
block to separate them, be extremely careful
not to gouge or nick the gasket surface of
either part; an oil leak could result.
11
Remove the oil pump pickup tube and
screen assembly (see illustrations).
12
Remove the oil pan from the vehicle
(see illustration).
13
Thoroughly clean all gasket sealing sur-
faces. Use a scraper to remove all traces of
old gasket material (see illustrations). Gas-
ket removal solvents are available at auto
parts stores and may prove helpful. Check
the oil pan sealing surface for distortion.
13.13b Remove the old gasket from the
oil pump pick up tube
2B-16
Chapter 2 Part B V6 engine
13.14 Apply a 1/8-inch bead of RTV
sealant to the oil pan sealing surface as
shown - stay on the inside of the
bolt holes
Straighten or replace as necessary. After
cleaning and straightening (if necessary),
wipe the gasket surfaces of the pan and
block clean with a rag soaked in lacquer thin-
ner or acetone.
Installation
Refer to illustration 13.14
14
Apply a 1/8-inch bead of RTV sealant to
the oil pan as shown (see illustration). Also
apply a light coating of RTV sealant to the
underside of the oil pan bolt heads.
15
Place the oil pan into position under the
engine block and install the oil pump pick-up
tube. Tighten the bolts to the torque listed in
this Chapter's Specifications.
16
Place the oil pan against the engine
block and install the bolts. Working from the
center and proceeding outward in a criss-
cross pattern, tighten the oil pan bolts to the
torque listed in this Chapter's Specifications.
17
The remaining installation steps are the
reverse of removal.
18
Lower the vehicle and fill the crankcase
with the proper quantity and grade of engine
oil (see Recommended lubricants and fluids
at the beginning of Chapter 1) and run the
engine, checking for leaks. Road test the
vehicle and check for leaks again.
14 Oil pump - removal, inspection
and installation
Removal
Refer to illustrations 14.7, 14.8, 14.9 and
14.10
1
Disconnect the negative battery cable
from the ground stud on the left shock tower
(see Chapter 5, Section 1).
2
Raise the vehicle and support it securely
on jackstands.
3
Remove the drivebelts (see Chapter 1).
4
Remove the timing belt (see Section 6)
and crankshaft sprocket and Woodruff key
(see Section 7).
5
Remove the oil pan (see Section 13).
6
If equipped, remove the air conditioning
compressor bracket from the engine and
position it out of the way.
7
Remove the bolts and detach the oil
pump assembly from the engine (see illus-
tration). Caution: If the pump doesn't come
off by hand, tap it gently with a soft-faced
hammer or pry on a casting boss.
8
Remove the oil filter passage 0-ring
14.7 Remove the oil pump assembly mounting bolts (arrows) and
detach it from the engine - bolt (A) also secures the air
conditioning compressor bracket (if equipped)
14.8 The oil filter passage 0-ring seals (arrows) may remained
attached to the engine block
14.9 Remove the rotor cover mounting screws (arrows)
14.10 The alignment mark has worn off the inner rotor on this oil
pump; in this case we'll use a permanent marker to match-mark
the rotors for reinstallation - oil pressure relief cap bolt (A)
Chapter 2 Part B V6 engine
2B-17
14.16a Install the rotors into the oil pump
body with the match marks aligned
14.16b Use a feeler gauge to measure the
inner rotor-to-outer rotor lobe clearance
14.16c Measuring the outer rotor-to-
pump body clearance
seals and discard them. They may stick to
the engine block as shown (see illustration)
or remain in the oil pump housing.
9
Remove the oil pump rotor cover (see
illustration).
10
New rotors are manufactured with
arrows on them which are aligned at installa-
tion. If both arrows are not clearly visible (see
illustration), use a permanent marker to
match-mark the rotors so they can be
installed back in their original position.
Remove the inner and outer rotor from the
body. Caution: Be very careful with these
components. Close tolerances are critical in
creating the correct oil pressure. Any nicks or
other damage will require replacement of the
complete pump assembly.
11
Using a hammer and drift, carefully and
evenly drive the crankshaft front seal from the
oil pump housing and discard it.
12
Disassemble the oil pressure relief valve
assembly, taking note of the way the relief
valve piston is installed. Unscrew the cap bolt
and remove the bolt, washer, spring and
relief valve (see illustration 14.10).
13
Thoroughly clean all gasket sealing sur-
faces. Use a scraper to remove all traces of
old gasket material. Gasket removal solvents
are available at auto parts stores and may
prove helpful. Check the oil pan sealing sur-
face for distortion. Straighten or replace as
necessary. After removing the residual gasket
material, wipe the gasket surfaces of the oil
pan and block clean with a rag soaked in lac-
quer thinner or acetone.
Inspection
Refer to illustrations 14.16a, 14.16b, 14.16c,
and 14.16d
14
Clean all oil pump components with sol-
vent and inspect them for excessive wear
and/or damage. Replace as required. Note: if
either rotor is damaged, they must be
replaced as a set.
15 Inspect the oil pressure relief valve pis-
ton sliding surface and valve spring for dam-
age. Note: If either the spring or the valve is
damaged, they must be replaced as a set.
16 Install the rotors into the pump housing
with the match-marks aligned (see illustra-
tion). Check the oil pump rotor clearances
using a precision straightedge and feeler
gauges (see illustrations). Compare the
results to the tolerances listed in this Chap-
ter's Specifications. Replace both rotors if
any clearance is out of tolerance.
Installation
Refer to illustration 14.19
17
Lubricate the relief valve piston, piston
bore and spring with clean engine oil. Install
the relief valve piston into the bore maintain-
ing original orientation followed by the spring
and cap bolt. Tighten the cap bolt to the
torque listed in this Chapter's Specifications.
Note: If the relief valve piston is installed
incorrectly, serious engine damage could
occur.
18
Lubricate the oil pump rotor recess in
the housing and the inner and outer rotors
with clean engine oil. Install the rotors into the
pump housing with the match-marks aligned
(see illustration 14.16a). Next, fill the rotor
cavity with clean engine oil and install the
cover. Tighten the cover screws to the torque
li sted in this Chapter's Specifications.
19 Install new 0-ring seals in the oil pump
passages located on the pump body (see
illustration). If necessary, apply a light coat-
ing of grease on the 0-rings to hold them in
place.
20 Install the new crankshaft front seal into
the oil pump housing (see Section 7).
21
Apply a 1/8 inch bead of anaerobic
sealant to the oil pump body sealing surface,
2B
14.16d Place a precision straightedge over the rotors and
measure the clearance between the rotors and the straightedge
to determine the rotor-to-cover clearance
14.19 Install new 0-ring seals on the oil filter passages (arrows)
2B-18
Chapter 2 Part B V6 engine
15.5 Remove the flywheel/driveplate from the crankshaft
16.3 Carefully
pry
the crankshaft seal out of the bore - DO NOT
nick or scratch the crankshaft or seal bore
and position the pump assembly on the block
aligning the inner rotor and crankshaft drive
flats. Install the mounting bolts.
22 If equipped, install the air conditioning
bracket onto the engine (one bolt secures
both the air conditioning bracket and the oil
pump housing).
23
Tighten the oil pump attaching bolts
(see illustration 14.7) to the torque listed in
this Chapter's Specifications.
24 Install the Woodruff key, crankshaft tim-
ing belt sprocket (see Section 7) and timing
belt (see Section 6).
25 Install the oil pan (see Section 13).
26 If applicable, install a new oil filter (see
Chapter 1).
27
The remaining installation steps are the
reverse of removal.
28
Lower the vehicle and fill the crankcase
with the proper quantity and grade of oil (see
Recommended lubricants and fluids Section
in Chapter 1).
29
Connect the negative battery cable to
the ground stud.
30
After the sealant has cured per the man-
ufacturer's directions, start the engine and
check for leaks.
15
Driveplate - removal and
installation
Removal
Refer to
illustration 15.5
1
Raise the vehicle and support it securely
on jackstands.
2
Remove the transaxle assembly (see
Chapter 7).
3
To ensure correct alignment during rein-
stallation, match-mark the backing plate and
driveplate to the crankshaft before removal.
4
Remove the bolts securing the drive-
plate to the crankshaft. A tool is available a
most auto parts stores to hold the driveplate
while loosening the bolts, if the tool is not
available, wedge a screwdriver in the ring
gear teeth to jam the driveplate.
5
Remove the driveplate from the crank-
shaft (see illustration).
6
Clean the driveplate to remove any
grease and oil. Inspect it for cracks, distortion
and missing or excessively worn ring gear
teeth. Replace if necessary.
7
Clean and inspect the mating surfaces
of the driveplate and the crankshaft. Check
the crankshaft rear main seal for leakage; if
leakage is evident replace it before rein-
stalling the driveplate (see Section 16).
Installation
8
Position the driveplate and backing
plate against the crankshaft. Align the previ-
ously applied match marks. Before installing
the bolts, apply thread locking compound to
the threads.
9
Hold the driveplate with the special
holding tool, or wedge
a
screwdriver in the
ring gear teeth to keep the driveplate from
turning as you tighten the bolts to the torque
li sted in this Chapter's Specifications.
10
The remaining installation steps are the
reverse of removal.
16
Rear main oil seal - replacement
Refer
to illustrations 16.3, 16.6 and 16.12
1
The crankshaft rear main oil seal is
pressed into a retainer and bolted to the rear
of the engine block.
2
Remove the driveplate (see Section 15).
3
The crankshaft rear main oil seal can be
renewed without removing the oil pan or seal
retainer. However, this method is NOT recom-
mended because the lip of the seal is quite
stiff and it's possible to cock the seal in the
retainer bore or damage it during installation.
If you want to take the chance, carefully and
evenly pry out the old seal using a 3/16 flat
blade screwdriver - do not to damage the
crankshaft sealing surface (see illustration).
Apply a light coating of clean engine oil to the
crankshaft seal journal and the lip of the new
seal then carefully tap the new seal into place
using a hammer and socket. The seal lip is
stiff, so carefully work it onto the seal journal
of the crankshaft with a smooth object like the
rounded end of a socket extension as you tap
the seal into place (see illustration 16.12).
Don't force it or you may damage the seal.
16.6 With the seal retainer supported on
wood blocks, use a hammer and drift to
drive the seal out of the retainer
4
The following method is recommended
and requires removal of the oil pan (see Sec-
tion 13).
5
Remove the mounting bolts from the
crankshaft rear seal retainer and separate the
retainer from the engine block.
6
Using a hammer and drift, carefully drive
the old seal out of the retainer and discard it
(see illustration).
7
Thoroughly clean all gasket sealing sur-
faces. Use a scraper to remove all traces of
old gasket material. Gasket removal solvents
are available at auto parts stores and may
prove helpful. Check the oil pan sealing sur-
face for distortion. Straighten or replace as
necessary. After removing the residual gasket
material, wipe the gasket surfaces clean
using a rag soaked in lacquer thinner or ace-
tone.
8
Thoroughly clean and inspect the seal
bore and sealing surface on the crankshaft.
Minor imperfections can be removed with
fine emery cloth. If there is a groove worn in
the crankshaft sealing surface (from contact
with the seal), installing a new seal will proba-
bly not stop the leak.
9
Install the new seal into the retainer
using a socket (or block of wood) and a ham-
mer. Drive it in until it's flush with the retainer.
Chapter 2 Part B V6 engine
2B-19
16.12 Using a rounded object like a socket extension, carefully
work the seal onto the crankshaft
17.9a Front engine mount (arrow) - exhaust manifold
removed for clarity
10
Apply a 1/8 inch bead of RTV sealant to
the retainer gasket sealing surface.
11
Lubricate the lip of the new seal and the
crankshaft sealing surface with a light coat of
clean engine oil.
12
Place the seal retainer in position on the
engine block and install the mounting bolts.
The seal lip is stiff, so carefully work it onto
the seal journal of the crankshaft with a
smooth object like the rounded end of a
socket extension as you tap the seal into
place (see illustration). Don't force it or you
may damage the seal. Tighten the bolts to the
torque listed in this Chapter's Specifications.
13 Install the oil pan (see Section 13).
14
The remaining installation steps are the
reverse of removal.
17 Engine mounts - check and
replacement
1
Engine mounts seldom require atten-
tion, but broken or deteriorated mounts
should be replaced immediately or the added
strain placed on the driveline components
may cause damage or wear.
Check
2
During the check, the engine must be
raised slightly to relieve the weight from the
mounts.
3
Raise the vehicle and support it securely
on jackstands, then position a jack under the
engine oil pan. Place a large wood block
between the jack head and the oil pan to pre-
vent oil pan damage, then carefully raise the
engine just enough to take the weight off the
mounts. Warning: DO NOT place any part of
your body under the engine when it's sup-
ported only by a jack!
4
Inspect the mounts to see if the rubber
is cracked, hardened or separated from the
metal backing. Sometimes the rubber will
split right down the center.
5
Check for relative movement between
the mount plates and the engine or frame
(use a large screwdriver or pry bar to attempt
to move the mounts). If movement is noted,
lower the engine and tighten the mount fas-
teners.
6
Rubber preservative may be applied to
the mounts to slow deterioration.
Replacement
Refer to illustrations 17.9a, 17.9b, 17.9c
17.9d and 17.9e
7
Disconnect the negative battery cable
from the ground stud on the left shock tower
(see Chapter 5, Section 1). Raise the vehicle
17.9b Rear engine mount - exhaust cross-
over pipe removed for clarity
and support it securely on jackstands.
8
Place a floor jack under the engine (with
a wood block between the jack head and oil
pan) and raise the engine slightly to relieve
the weight from the mount to be replaced.
Note: On 1995 through 1997 models, the
lower front engine mount (engine support
module) is attached to the lower radiator sup-
port. When removing the engine support
module, the radiator and air conditioning con-
denser (if equipped) must be supported.
9
Remove the fasteners and detach the
2B
17.9c Engine support module (arrow) - connects front and rear
engine mounts (1995 through 1997 models)
17.9d Right-side engine mount (arrow)
2B-20
Chapter 2 Part B V6 engine
mount from the frame and engine (see illus-
trations). Caution: Do not disconnect more
than one mount at a time, except during
engine/transaxle removal.
10 Installation is the reverse of removal.
Use thread locking compound on the mount
bolts and be sure to tighten them securely.
17.9e Transaxle
support assembly
and brackets
TRANSMISSION
SUPPORT
ASSEMBLY
TRANSMISSION
TRANSMISSION
BRACKET
LEFT
FRAME
RAIL
GROUND
CABLE
Chapter 2 Part C
General engine overhaul procedures
Contents
Section
Balance shafts (2.4L four-cylinder engines only) - removal,
inspection and installation. . . . . . . . . . . . . . . .. 15
Crankshaft inspection. . . . . . . . . . . . . . . . . . .. 21
Crankshaft installation and main bearing oil
clearance check . . . . . . . . . . . . . . . . . . . . 25
Crankshaft removal. . . . . . . . . . . . . . . . . . . ..16
Compression check . . . . . . . . . . . . . . . . . . . ...4
Cylinder head - cleaning and inspection . . . . . . . . . . . ..11
Cylinder head - disassembly . . . . . . . . . . . . . . . . 10
Cylinder head - reassembly. . . . . . . . . . . . . . . . . 13
Cylinder honing . . . . . . . . . . . . . . . . . . . . . 19
Engine block - cleaning. . . . . . . . . . . . . . . . . . 17
Engine block - inspection. . . . . . . . . . . . . . . . . .18
Engine overhaul - disassembly sequence . . . . . . . . . . . . 9
Engine overhaul - general information . . . . . . . . . . . . ... 2
Engine overhaul - reassembly sequence . . . . . . . . . . . .23
Section
Engine rebuilding alternatives. . . . . . . . . . . . . . . . 8
Engine - removal and installation . . . . . . . . . . . . . . ...7
Engine removal - methods and precautions . . . . . . . . . . ..6
General information . . . . . . . . . . . . . . . . . . . . 1
Initial start-up and break-in after overhaul . . . . . . . . . . ...27
Main and connecting rod bearings - inspection . . . . . . . . .. 22
Piston rings - installation. . . . . . . . . . . . . . . . . ..24
Pistons and connecting rods - inspection . . . . . . . . . . ... 20
Pistons and connecting rods - installation and
rod bearing oil clearance check . . . . . . . . . . . . . . 26
Pistons and connecting rods - removal . . . . . . . . . . . ...14
Rear main oil seal - installation. . . . . . . . . ...See Chapter 2B
Top Dead Center (TDC) for number one piston - locating . . . . . .3
Vacuum gauge diagnostic checks. . . . . . . . . . . . . . .5
Valves - servicing . . . . . . . . . . . . . . . . . . . . . 12
2C
Specifications
Four-cylinder engines
General
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke
2.0L. . . . . . . . . . . . . . . . . . . . . . . . .
2.4L. . . . . . . . . . . . . . . . . . . . . . . . .
Displacement
2.0L. . . . . . . . . . . . . . . . . . . . . . . . .
2.4L. . . . . . . . . . . . . . . . . . . . . . . . .
Compression ratio
2.0L. . . . . . . . . . . . . . . . . . . . . . . . .
2.4L. . . . . . . . . . . . . . . . . . . . . . . . .
Compression pressure . . . . . . . . . . . . . . . . . . .
Firing order. . . . . . . . . . . . . . . . . . . . . . . ..
Oil pressure
At idle speed. . . . . . . . . . . . . . . . . . . . . ..
At 3000 rpm . . . . . . . . . . . . . . . . . . . . . .
Cylinder head warpage
Head gasket surface. . . . . . . . . . . . . . . . . . ..
Intake/exhaust manifold mounting surfaces . . . . . . . . . ..
Valves and related components
Face angle
2.0L. . . . . . . . . . . . . . . . . . . . . . . . .
2.4L. . . . . . . . . . . . . . . . . . . . . . . . .
Seat angle . . . . . . . . . . . . . . . . . . . . . . . .
Valve margin width
2.0L
Intake. . . . . . . . . . . . . . . . . . . . . . .
Exhaust. . . . . . . . . . . . . . . . . . . . . . .
2.4L
Intake. . . . . . . . . . . . . . . . . . . . . . .
Exhaust. . . . . . . . . . . . . . . . . . . . . . .
3.4446 to 3.4452 inches
3.268 inches
3.976 inches
122 cubic inches
148 cubic inches
9.8:1
9.4:1
170 to 225 psi
1-3-4-2
4 psi (minimum)
25 to 80 psi
0.004 inch maximum
0.006 inch maximum
45 to 45-1/2 degrees
44-1/2 to 45 degrees
45 degrees
0.0452 to 0.0582 inch
0.058 to 0.071 inch
0.050 to 0.063 inch
0.038 to 0.051 inch
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